Medical device tray and method of forming the medical device tray

ABSTRACT

A medical device tray for carrying a plurality of medical devices includes: a base made of a substantially rigid material, the base forming at least one base through-hole that has an associated visual indicator; and a covering affixed to the base, the covering being made of a material which is softer than the substantially rigid material of the base and substantially transparent, the covering forming at least one covering through-hole, the at least one base through-hole and the at least one covering through-hole cooperating to form at least one medical device tray through-hole configured for directly supporting a respective one of the plurality of medical devices.

CROSS REFERENCE TO RELATED APPLICATIONS

This is a division of U.S. patent application Ser. No. 14/592,311,entitled “MEDICAL DEVICE TRAY AND METHOD OF FORMING THE MEDICAL DEVICETRAY,” filed Jan. 8, 2015, which is incorporated herein by reference.U.S. patent application Ser. No. 14/592,311 is a continuation-in-part ofU.S. patent application Ser. No. 14/157,811, entitled “MEDICAL DEVICETRAY AND METHOD OF FORMING THE MEDICAL DEVICE TRAY,” filed Jan. 17,2014, which is incorporated herein by reference.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates to trays, and, more particularly, tomedical device trays.

2. Description of the Related Art

A surgical tool container system is known which can hold surgical toolsfor purposes of organization and sterilization. Such a system includes atool holding tray with a plurality of holes. Elastomeric grommets arefixedly secured within a respective hole to removably secure surgicaltools to the tray. A disadvantage of using such grommets is that thegrommets can be difficult to sterilize.

Dental trays, for example, can be used to hold dental devices. By usingsuch a tray, the dental devices are stored on the tray in an organizedmanner, which helps the dentist to quickly identify the proper deviceduring a dental procedure. A dental tray is known which usesindividually positioned grommets (for example, silicone rivets) orinserts to hold dental devices (for example, dental instruments) in thedental tray. The individual grommets are difficult to clean andsterilize. There is the possibility that blood and organic particulatematter may be trapped in the grommets. For example, grommets assembledin radel or metal trays present areas where biological contaminants,such as dried blood or tissues could be trapped; these contaminants aredifficult to remove during cleaning and sterilization.

What is needed in the art is a medical device tray that is simple indesign and relatively easy to sterilize.

SUMMARY OF THE INVENTION

The present invention provides a medical device tray that does not usegrommets or inserts to hold the dental devices.

The invention in one form is directed to a medical device tray forcarrying a plurality of medical devices. The medical device trayincludes: a base made of a substantially rigid material, the baseforming at least one base through-hole, the at least one basethrough-hole having an associated visual indicator; and a coveringaffixed to the base, the covering being made of a material which issofter than the substantially rigid material of the base andsubstantially transparent, the covering forming at least one coveringthrough-hole, the at least one base through-hole and the at least onecovering through-hole cooperating to form at least one medical devicetray through-hole configured for directly supporting a respective one ofthe plurality of medical devices.

The invention in another form is directed to a medical device traysystem. The medical device tray system includes: a medical device; and amedical device tray configured for carrying a plurality of the medicaldevice. The medical device tray includes: a base made of a substantiallyrigid material, the base forming at least one base through-hole, the atleast one base through-hole having an associated visual indicator; and acovering affixed to the base, the covering being made of a materialwhich is softer than the substantially rigid material of the base andsubstantially transparent, the covering forming at least one coveringthrough-hole, the at least one base through-hole and the at least onecovering through-hole cooperating to form at least one medical devicetray through-hole directly supporting the medical device.

The invention in yet another form is directed to a method of forming amedical device tray for carrying a plurality of medical devices. Themethod includes the steps of: providing a base made of a substantiallyrigid material, the base forming at least one base through-hole; forminga visual indicator on the base adjacent to the at least one basethrough-hole; affixing a covering to the base, the covering being madeof a material which is softer than the substantially rigid material ofthe base and substantially transparent, the covering forming at leastone covering through-hole, the at least one base through-hole and the atleast one covering through-hole cooperating to form at least one medicaldevice tray through-hole; supporting directly a respective one of theplurality of medical devices.

An advantage of the present invention is that it eliminates theindividual grommets, thereby reducing the undercuts and corners whereblood and/or other organic particulate matter may be trapped.

Another advantage is of the present invention is that it provides asimple and low cost method of reducing the biological contaminationrisks associated with surgical instrument trays (for example, but notlimited to, dental surgery trays). The present invention is thusadvantageous technically and from a cost point-of-view over a designthat uses grommets.

Yet another advantage of the present advantage is that the visualindicators associated with the through-holes can be seen through andprotected by the covering, which can extend the lifetime of the visualindicators.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features and advantages of this invention,and the manner of attaining them, will become more apparent and theinvention will be better understood by reference to the followingdescription of embodiments of the invention taken in conjunction withthe accompanying drawings, wherein:

FIG. 1 is a perspective view of a dental tray system according to thepresent invention;

FIG. 2 is a bottom view of the dental tray of the dental tray system ofFIG. 1;

FIG. 3 is a perspective view of the base of the dental tray of FIG. 1;

FIG. 4 is a perspective view of another embodiment of a dental traysystem according to the present invention, with portions broken away;

FIG. 5 is a bottom view of the dental tray of the dental tray system ofFIG. 4, with portions broken away;

FIG. 6 is a top view of yet another embodiment of a dental trayaccording to the present invention;

FIG. 7 is a perspective view of yet another embodiment of a dental trayaccording to the present invention; and

FIG. 8 is another perspective view of the dental tray shown in FIG. 7.

Corresponding reference characters indicate corresponding partsthroughout the several views. The exemplifications set out hereinillustrate embodiments of the invention, and such exemplifications arenot to be construed as limiting the scope of the invention in anymanner.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings, and more particularly to FIGS. 1-3, thereis shown, according to one embodiment of the present invention, amedical device tray system 10 which generally includes a medical devicetray 11 and a medical device 12. Medical device tray 11 is configuredfor carrying a plurality of medical devices 12.

The medical device tray of the present invention has application tovirtually any medical field. In other words, the medical device tray ofthe present invention (for example, medical device tray 11) can be usedto carry medical devices used in medical procedures concerning teeth,feet, hands, shoulders, the spine, or virtually any other part of acorporeal body. Further, the medical device tray and the medical deviceof the present invention can be respectively a tray and a device usedfor medical procedures concerning human beings or for veterinaryprocedures (for animals). Further, the medical devices of the presentinvention can be implants, tools, implements, instruments, or virtuallyany medical device that can be carried by a tray; such medical devicesinclude, for example, small medical instruments. By way of example andnot by way of limitation, the description that follows describes anexemplary application of the present invention. That is, the medicaldevice tray system, the medical device tray, and the medical devicedescribed herein is applied to the medical field of dentistry. Thus, themedical device tray system, the medical device tray, and the medicaldevice described herein are, respectively, a dental tray system, adental device, and a dental device. Thus, according to one embodiment ofthe present invention, medical device tray system 10, medical devicetray 11, and medical device 12 are, respectively, dental tray system 10,dental tray 11, and dental device 12. However, as indicated, the presentinvention is not limited to the field of dentistry.

Thus, FIGS. 1-3 show, according to one embodiment of the presentinvention, dental tray system 10 which generally includes dental trayand dental device 12. Dental tray 11 is configured for carrying aplurality of dental devices 12. Dental tray 11 generally includes a base14 and a covering 16 affixed to base 14. Dental tray 11 can be used by adental or dental assistant during a dental procedure.

Dental device 12 can be various dental devices which are used in dentalprocedures and which can be held in a dental tray. These dentalinstruments can be relatively small. For example, the dental device heldby the dental tray of the present invention can be, for example, adrill, a screwdriver, an awl, a dental burr, or another device; theseexamples are provided by way of example and not by way of limitation.Two dental devices 12 are shown in FIG. 1; both dental devices are thesame in size and shape. One dental device 12 in FIG. 1 is exploded fromdental tray 11, and the other dental device 12 is shown positioned in ahole (covering through-hole 24) in dental tray 11. Dental device 12shown in FIG. 1 is a hex screwdriver, the hexagonal head being at thetop of the device shown in FIG. 1 (dental device 12 is not shown in FIG.2). Dental device 12, as shown in FIG. 1, includes a dental adapter 13.Covering 16 of dental tray 11 (in particular, the silicone, for example,of covering 16) can hold dental device 12. For example, the internaldiameter of covering 16 (at a covering through-hole 24) can be water jetcut to approximately 1.66 mm, and dental adapter can have a diameter of2.35 mm; in this way, an interference between the material of cover 16(such as silicone) and dental device 12 ensures that cover 16 holdsdental device 12 (by way of an interference fit) and prevents dentaldevice 12 from falling through covering through-hole 24. This dimensionof covering through-hole 24 can be taken from either the outer radius ofcovering through-hole 24 (the outer radius being the widest radius ofcovering through-hole 24) or the inner radius of covering through-hole24 (the inner radius being taken from where the radially inner tips ofthe projections forming through-hole 24 project inwardly, coverthrough-holes 24 in FIG. 1 having essentially three such inwardlyextending projections). These dimensions, and this means of holding, areprovided as merely one example and are thus not provided by way oflimitation. The cutout shown at the bottom of dental device 12 in FIG. 1is also an adapter that allows dental device 12 to be attached to amotor or to a handle. The material of dental device 12 can be stainlesssteel (adapter 13 can also be stainless steel or can be anothermaterial, such as a resilient material).

Base 14 of dental tray 11 is made of a substantially rigid material. Inthis way, base 14 provides a stable structure that can be placed on atable for instance; base 14 provides rigidity for dental tray 11. Thesubstantially rigid material of base 14 can metallic, plastic, anothermaterial sheet to guarantee rigidity, or another rigid material. Ifmetal is used, the material can be, for example, stainless steel, suchas medical grade stainless steel; this material is provided by way ofexample and not by way of limitation. Base 14 can be formed by molding,machining, stamping, pressing, bending, and/or any other suitablemethod. FIG. 3 shows that base 14 includes a central frame 18 and twolegs 20 depending downwardly from central frame 18.

FIG. 3 shows one embodiment of base 14 according to the presentinvention, base 14 being shown by itself and thus without covering 16.As shown in FIG. 3, base 14 forms at least one base through-hole 22.FIG. 3 shows that central frame 18 can include a plurality of basethrough-holes 22. FIG. 3 shows eight such base through-holes 22, butmore or less such base through-holes 22 can be used. Each leg 20 dependsfrom a longitudinal side of central frame 18; each leg 20 can include,for example, a plurality of through-holes, as shown in FIGS. 1 and 3.Base 14 can be considered a plate 14.

Covering 16 of dental tray 11 is made of a material which is softer thanthe substantially rigid material of base 14. The material of covering 16can be a biocompatible soft material, such as silicone, santoprene, oranother suitable material; this material is provided by way of exampleand not by way of limitation. According to one embodiment of the presentinvention (such as the embodiment shown in FIGS. 1-3), covering 16 isformed by injection molding. More specifically, according to thisembodiment of the present invention, covering 16 is overmolded onto base14, in particular, over central frame 18 of base 14. Stated another way,the step of affixing includes injection molding a material of covering16 and thereby overmolding covering 16 onto base 14. Thus, for example,the stainless steel plate 14 (the base 14) can be overmolded withsilicone to form covering 16 on base 14. Covering 16 forms at least onecovering through-hole 24. FIGS. 1 and 2 show that covering 16 includesseveral such covering through-holes 24. Covering through-holes 24 can besubstantially perpendicular to the top and bottom surfaces of covering16. For instance, FIGS. 1 and 2 show that covering 16 can include eightrows of four such covering through-holes 24. According to one designexample, covering through-holes 24 at one longitudinal end of dentaltray 11 can be smaller than covering through-holes 24 at the otherlongitudinal end of dental tray 11 (this is shown in the drawings).After overmolding covering 16 over central frame 18 of base 14, coveringthrough-holes 24 can be cut into covering 16 (central frame 18 alreadyhas eight large holes 22). Covering through-holes 24 can be formed by,for example, a water jet (by water jet cutting), a laser (by lasercutting), or another suitable process. These methods of cutting areprovided by way of example and not by way of limitation. Thus, themethod of the present invention can include cutting at least onecovering through-hole 24 in covering 16 by water jet cutting or lasercutting. Through-holes 24 cut into covering 16 thus form featuresconfigured for holding the dental devices 12, such as dental surgeryinstruments. These holes 24 in the covering 16 are thus through-holes 24which allow the dental devices 12 to extend through the overmoldedcovering 16. These holes 24 can be formed such that they areperpendicular to both the top side and the bottom side of the covering16. FIG. 3 shows that base 14 of one embodiment includes eight basethrough-holes 22 formed in central frame 18 of base 14. Each of thesebase through-holes 22 is rather large compared to each one of coveringthrough-holes 24 in FIGS. 1 and 2; thus, a plurality of coveringthrough-holes 24 are associated with a respective one of basethrough-holes 22 (for example, comparing FIGS. 2 and 3, four suchcovering through-holes 24 can be associated respectively with each basethrough-hole 22).

The overmolding operation provides that each base through-hole 22 isfilled by the material of covering 16. Stated another way, the materialof covering 16 flows over central frame 18 and bonds (or becomesotherwise affixed) thereto and is shaped by the mold to fill the spaces22 (the base through-holes 22) formed by central frame 18. Thus, basethrough-hole 22 is filled by covering 16 and includes therethrough theplurality of covering through-holes 24 which define a plurality ofdental tray through-holes 25 (which, as indicated above, can moregenerally be referred to as medical device tray through-holes 25). Arespective base through-hole 22 includes a plurality of coveringthrough-holes 24 in the sense that such covering through-holes 24 extendthrough the material of covering 16, this covering material beingpositioned in and thereby filling this respective base through-hole 22.In this way, at least one base through-hole 22 and at least one coveringthrough-hole 24 cooperate with one another to form at least one dentaltray through-hole 25 (which can more generally be referred to as medicaldevice tray through-hole 25) configured for directly supporting arespective one of the plurality of dental devices 12 (which can moregenerally be referred to as medical devices 12). FIG. 1 shows dentaltray through-hole 25 directly supporting dental device 12. Withreference to the embodiment of the dental tray 11 of the presentinvention shown in FIGS. 1-3, this cooperation thus occurs in the sensethat the larger base through-hole 22 is filled with the coveringmaterial, and the covering material includes at least one coveringthrough-hole 24 therethrough which is positioned in this larger basethrough-hole 22; in this way, a respective covering through-hole 24alone forms the actual respective dental tray through-hole 25, and thecovering through-holes 24 and the dental tray through-holes 25 are thesame structure in this particular embodiment of the dental tray of thepresent invention. Further, the respective dental tray through-hole 25supports the respective dental device 12 without using a grommet orinsert to hold the dental device 12 in dental tray through-hole 25; inother words, dental tray 11 (which can be referred to as a medicaldevice tray 11) has an absence of a grommet or insert which isconfigured for holding the respective one of the plurality of dentaldevices 12 (which can be referred to as a medical devices 12). Dentalthrough-hole 25 receives and supports the respective dental device byway of, for example, an interference fit, a friction fit, or a wideningsection on the dental device which catches on the top surface ofcovering 16 and thereby prevents the dental device from “falling”through the respective dental through-hole 25 (these examples areprovided merely by way of example and not by way of limitation). Forexample, in one embodiment, the diameter of adapter 13 can be largerthan the inner radius (formed by the tips of the inwardly extendingprojections) of covering through-hole 24 (but smaller than the outerradius of covering through-hole 24) and be held by the radially inwardlyextending projections of covering through-hole 24 by an interferencefit. In this alternative, holes may exist radially outwardly of adapter13 so that steam can travel upwardly through these holes betweenadapater 13 and covering through-hole 24 during cleaning and/orsterilizing processes. Alternatively, the diameter of adapter 13 can beslightly larger than the outer radius of covering through-hole 24 butcan still be press fit into covering through-hole 24 to be held bycovering through-hole 24 by an interference fit (for instance, due tothe resilience of the material of covering 16).

After overmolding covering 16 over base 14 and cutting through-holes 24in covering 16 to hold the dental devices 12 (i.e., dental instruments12), covering 16 can be marked. That is, a marking 26 can be applied onthe soft material of covering for purposes of color coding. FIG. 1 showsthe top side of covering, the top side of covering being shown withcircular markings 26 around four adjacent rows of covering through-holes24. Each row of circular markings 26 can be a different color relativeto the other rows of circular markings 26. For example, each of thecircular markings 26 in the first row (the row having circular markings26 and being nearest the transverse edge of dental tray 11) can becolored white. Each of the circular markings 26 in the second row can becolored red. Each of the circular markings 26 in the third row can becolored yellow. Each of the circular markings 26 in the fourth row canbe colored blue. This arrangement of colors is provided by way ofexample and not by way of limitation. The purpose of the color coding isto help the dentist organize the dental devices 12 on the dental tray 11into logical groupings. The color markings 26 can be placed on covering16 by way of silk screen printing, for example; this process is providedby way of example and not by way of limitation. In this way, an inkmarking (a respective color marking 26) can be printed on covering 16.After performing sterilization and detergent tests on some samples, theink appeared to be resistant (resistant to being removed from thecovering).

FIGS. 4 and 5 show another embodiment of the dental tray according tothe present invention. The dental tray 111 of FIGS. 4-5 is similar tothe dental tray 11 of FIGS. 1-3. Certain ones of the differences arehighlighted herein. Structural elements in FIGS. 4-5 which are similarto that shown and described relative to the embodiment of FIGS. 1-3 areprovided with a reference number raised by 100 relative to similarstructures in FIGS. 1-3, even if the structures are not exactlyidentical. It is understood that a dental device 12 can be held in anyone of the dental tray through-holes 125 of dental tray 111 and therebyform a dental system, similar to that described and shown with referenceto FIGS. 1-3 (dental device is shown in FIG. 4 but not in FIG. 5).Dental system 110 includes dental tray 111 of FIGS. 4-5, dental tray 111including base 114 and covering 116.

Base 114 can be made of the same material and in the same manner asdescribed above relative to FIGS. 1-3. Base 114 includes central frame118 and legs 120 depending from central frame 118. Central frame 118,however, has more material than the embodiment described above. Basethrough-holes 122 are generally circular through-holes. The size andshape of base through-holes 122 can vary from row-to-row or in anymanner so desired. Further, FIGS. 4 and 5 show that two additional,smaller holes can be formed in central frame 118 at opposing corners.Central frame 118 of base 114 includes a top side 128 and a bottom side130.

Covering 116 of FIGS. 4-5 can be made of the same material as describedabove relative to FIGS. 1-3. FIGS. 4-5 show that covering 116 includes atop layer 132 and a bottom layer 134. Each layer 132, 134 issubstantially identical to one another. Top layer 132 is mounted to topside 128 of base 114. Bottom layer 134 is mounted to bottom side 130 ofbase 114. In this way, as shown in FIG. 4, top and bottom layers 132,134 of covering 116 sandwich central frame 118 of base 114. Top andbottom layers 132, 134 of covering 116 can be bonded to central frame118 of base 114, such as by using an adhesive, such as silicone glue;this way of attachment is provided by way of example and not by way oflimitation.

Covering 116 includes covering through-holes 124. Top layer 132 andbottom layer 134 can be considered two halves of covering 116. In thissense, each covering through-hole 124 has a first half 136 and a secondhalf 138, first half 136 being formed by top layer 132, second half 138being formed by bottom layer 134. Because top and bottom layers 132, 134of covering 116 sandwich base 114, first and second halves 136, 138 ofeach covering through-hole 124 are spaced apart from one another but yetare considered to form together a respective covering through-hole 124.Top layer 132 includes first half 136 of at least one coveringthrough-hole 124, and bottom layer 134 includes second half 138 of atleast one covering through-hole 124. Thus, each layer 132, 134 hasthrough-holes cut in substantially the same place as the other, thesethrough-holes being cut in substantially the same size and shaperelative to one another. In this way, first and second halves 136, 138of at least one covering through-hole 124 are substantially aligned withone another. Further, first and second halves 136, 138 are positionedrelative to at least one base through-hole 122 such that first half 136,second half 138, and at least one base through-hole 122 together form atleast one dental tray through-hole 125 (which can be referred to asmedical device tray through-hole 125). In this way, a respective basethrough-hole 122 and a respective covering through-hole 124 cooperate toform at least one dental tray through-hole 125 configured for directlysupporting a respective one of the plurality of dental devices 12.Indeed, base through-hole 122 and covering through-hole 124 cooperate toform a dental tray through-hole 125 which directly supports a dentaldevice 12. FIG. 5 shows a bottom view of dental tray but without bottomlayer 134 of covering 116. Thus, FIG. 5 shows base 114, and portions oftop layer 132 of covering 116 can be seen through base through-holes 122in base 114. FIG. 5 thus shows that each base through-hole 122 has aradius which is as large as or larger than the outer radius of firsthalf 136 of covering through-hole 124 formed in top layer 132 (the sameis true relative to bottom layer 134). Because the material of top andbottom layers 132, 134 extend radially inwardly of base through-hole122, a gap which is not filled by base 114 can be formed between top andbottom layer 132, 134.

Covering through-holes 122 (as well as the holes in legs 120 of base114) can be formed in base 114 before layers 132, 134 of cover 116 areattached to base 114. First and second halves 136, 138 of coveringthrough-holes 124 in top and bottom layers 132, 134 can be cut (asdescribed above) either before layers 132, 134 are attached to base 114or after layers 132, 134 are attached to base 114. Layers 132, 134 ofcovering 114 can be individually formed by molding (for example,injection molding), cutting from a blank, or another suitable method.First and second halves 136, 138 of covering through-holes 124, as wellas base through-holes 122, can be substantially perpendicular to the topsurface and the bottom surface of covering 116.

As stated above, dental through-hole 125 supports the respective dentaldevice by way of, for example, an interference fit, a friction fit, or awidening section on the dental device which catches on the top surfaceof covering 116 and thereby prevents the dental device from “falling”through the respective dental through-hole 125 (these examples areprovided merely by way of example and not by way of limitation).Further, the respective dental tray through-hole 125 receives andsupports the respective dental device without using a grommet or insertto hold the dental device in dental tray through-hole 125; in otherwords, dental tray 111 (which can be referred to as a medical devicetray 111) has an absence of a grommet or insert which is configured forholding the respective one of the plurality of dental devices (which canbe referred to as a medical devices). Covering through-holes 124 canhold the dental device in a similar way to (and thus function similarto) what has been described relative to the embodiment shown in FIGS.1-3.

FIG. 6 shows a top view of yet another embodiment of the dental trayaccording to the present invention. The dental tray of FIG. 6 is similarto the dental trays 11 and 111 of FIGS. 1-5. Certain ones of thedifferences are highlighted herein. Structural elements in FIG. 6 whichare similar to that shown and described relative to the embodiment ofFIGS. 1-3 are provided with a reference number raised by 200 relative tosimilar structures in FIGS. 1-3, even if the structures are not exactlyidentical. It is understood that a dental device 12 can be held in thedental through-hole 225 of dental tray 211 and thereby form a dentalsystem, similar to that described and shown with reference to FIGS. 1-3.A dental device is not shown in FIG. 6.

Dental tray 211 includes base 214 and covering 216. Like covering 116,covering 216 has two layers, only top layer 232 being shown in FIG. 6.Covering 216 includes additional holes. Covering 216 includes holes 240.FIG. 6 shows holes 240 positioned radially outside of coveringthrough-holes 224. Each layer of covering 216 includes holes 240, holes240 in each layer being substantially aligned relative to one another.The radius of base through-holes (not shown in FIG. 6) is as large as orlarger than an outer radius associated with holes 240 and running fromthe center of covering through-holes 224 to the radial outer extent ofholes 240. In this way, an unobstructed path is created between holes240 in the top and bottom layers of covering 216. Alternatively, base214 can include similarly sized and shaped holes relative to holes 240such that holes 240 in the top and bottom layers of covering 216 aresubstantially aligned with similar holes in base 214. The purpose ofholes 240 is to allow steam to travel through dental tray 211, such asfrom the bottom of dental tray 211 to the top of dental tray 211; inthis way, cleaning and sterilization of dental tray 211 can be improved.Covering through-holes 224 can hold the dental device in a similar wayto (and thus function similar to) what has been described relative tothe embodiment shown in FIGS. 1-5.

While not shown in the drawings, the dental tray of the presentinvention can be held, carried, transported, or otherwise supported in acontainer. The container has a base and a lid which pivots relative tothe container base. The legs of the dental tray rest on the bottom ofthe container base. The lid can have through-holes therein to facilitatecleaning and/or sterilizing the dental tray contained therein.

Each of the embodiments of the dental tray of the present invention canbe used essentially in the same manner. Thus, in use, the dental traycan be stored and/or transported in the container. The dental tray caneither remain in the container or be removed from the container whenused during a dental procedure by a dentist. For instance, the dentaltray can be removed from the container and placed on a table or otherplatform used during a medical procedure. Either way, a dental devicecan be held directly by the through-holes through the covering and baseof the dental tray without the need for a grommet or any other holdingdevice inserted into the holes of the covering. Each of the holes canhold a dental device. The holes can be sized and/or shaped differentlyto hold different sorts of dental devices. The dental device can beinserted into a respective dental tray through-hole by inserting thedental device from the top of the dental tray.

According to the main purpose of the dental tray of the presentinvention, the dental tray is designed to eliminate the individualgrommets and to erase any possibility (or at least to reduce thepossibility) of potentially contaminated areas. According to a secondarypurpose of the dental tray of the present invention, the dental tray canbe designed to be compatible with sterilizing process machines. Further,according to design choice, the dental tray can be designed to bewashing machine compatible such that dental instruments are fitted in(that is, present in) the tray during washing and sterilization.Further, according to design choice, the exact size and position of thecontact points between the dental instruments and the soft material (thecovering) can be optimized so as to ensure the correct flow of washingand sterilizing fluids through the dental tray.

The present invention further provides a method of forming a medicaldevice tray 11, 111 for carrying a plurality of medical devices 12, 112.The method includes the steps of: providing a base 14, 114 made of asubstantially rigid material, base 14, 114 forming at least one basethrough-hole 22, 122; affixing a covering 16, 116 to base 14, 114,covering 16, 116 being made of a material which is softer than thesubstantially rigid material of base 14, 114, covering 16, 116 formingat least one covering through-hole 24, 124, at least one basethrough-hole 22, 122 and at least one covering through-hole 24, 124cooperating to form at least one medical device tray through-hole 25,125; supporting directly a respective one of the plurality of dentaldevices 12, 112. The substantially rigid material of base 14, 114 isstainless steel. The material of covering 16, 116 is biocompatible andis silicone or santoprene. Medical device tray 11, 111 has an absence ofa grommet configured for holding the respective one of the plurality ofmedical devices 12, 112. The step of affixing includes overmoldingcovering 16 onto base 14. The at least one covering through-hole 24includes a plurality of covering through-hole 24, base through-hole 22being filled by covering 16 and including therethrough the plurality ofcovering through-holes 24 which define a plurality of the at least onemedical device tray through-hole 25. Base 114 includes a top side 128and a bottom side 130, covering 116 including a top layer 132 and abottom layer 134, top layer 132 being mounted to top side 128, bottomlayer 134 being mounted to bottom side 130, top layer 134 including afirst half 136 of the at least one covering through-hole 124, bottomlayer 134 including a second half 138 of the at least one coveringthrough-hole 124, first half 136 of the at least one coveringthrough-hole 124 and second half 138 of the at least one coveringthrough-hole 124 being substantially aligned with one another andpositioned relative to the at least one base through-hole 122 such thatfirst half 136, second half 138, and the at least one base through-hole122 together form the at least one medical device tray through-hole 125.The step of affixing includes injection molding a material of covering16 and thereby overmolding covering 16 onto base 14, the method furtherincluding cutting at least one covering through-hole 24 in covering 16by water jet cutting or laser cutting. The method can further includeprinting an ink marking 26 on covering 16.

Referring now to FIGS. 7 and 8, a medical device tray 311 is shown thatis similar to previously described medical device trays 11, 111 and 211.The medical device tray 311 includes a base 314 and covering 316 that isaffixed to the base 314. The base 314 is comprised of a substantiallyrigid material, such as stainless steel, and has at least one basethrough-hole 322 formed through. Unlike previously described medicaldevice trays 11, 111 and 211, the base 314 of medical device tray 311has visual indicators 326 associated with at least one of the basethrough-holes 322 that are formed on the base 314. As used herein,“associated with” means that the visual indicator 326 is sufficientlyclose to its associated base through-hole 322 to relay some type ofinformation about the base through-hole 322. Therefore, the visualindicator 326 will be in relatively close proximity to its associatedbase through-hole 322 so that a user viewing the medical device tray 311can associate the visual indicator 326 with the associated basethrough-hole 322 and obtain some type of information indicated by thevisual indicator 326. For example, the visual indicator could be a redmarking that surrounds one or more base through-holes and indicates thatany instruments held in the base through-hole(s) surrounded by redmarking have already been used and are not clean. Such a configurationis merely an example of how a visual indicator 326 could be usefullyincluded in the base 314 of the medical device tray 311. The visualindicator(s) 326 could take a variety of forms, including ink markings,notches, and indicating openings. Each form of visual indicator(s) 326could also have a variety of shapes, colors and sizes. The shapes caninclude geometric shapes, letters, and words. In this regard, theexamples given show that a wide variety of visual indicators can beapplied to the base 314 and associated with base through-holes 322 toconveniently provide a user with information about the basethrough-hole(s) 322 or provide a convenient way to organize medicaldevices in the tray 311. As shown in FIG. 7, multiple base through-holes322 can be arranged in through-hole groupings 328, 330, 332 and 334 toprovide a convenient way of organizing medical devices in the tray 311.Each through-hole grouping 328, 330, 332 and 334 can have respectivebase through-holes 322 with similar associated visual indicators 326.For example, the visual indicators 326 in through-hole grouping 328could all be formed as blue circles that surround an associated basethrough-opening. The blue circles could indicate that a medical deviceheld in the associated base through-opening is clean and suitable foruse. In addition to color, the similar visual indicators 326 of athrough-hole grouping could have similar sizes, shapes and locations onthe base 314.

As shown in FIG. 8, one or more base through-holes 322 could havemultiple associated visual indicators 326 to differentiate between otherbase through-holes 322 in a through-hole grouping 328, 330, 332, 334.Base through-hole 336 in through-hole grouping 330, for example, has avisual indicator 338, shown as an ink circle, that surrounds basethrough-hole 336 as well as a nearby visual indicator 340, shown asinked letter coding. The combination of visual indicators 338 and 340make it more convenient for a user to keep the same surgical instrumentheld within base through-hole 336 throughout a surgery.

A covering 316 is affixed to the base 314 in a similar fashion topreviously described coverings 16, 116 and 216. Also similar topreviously described coverings 16, 116 and 216, covering 316 has atleast one covering through-hole 324 formed through that will cooperatewith a base through-hole 322 to form a medical device tray through-hole325 that will directly support a medical instrument during use of thetray 311. Since the covering 316 will be placed over the base 314, thematerial that forms that covering 316 should be substantiallytransparent so that the visual indicator(s) 326 formed on the base 314can be seen through the covering 316. As used herein, “substantiallytransparent” does not mean “completely transparent,” but transparentenough that the visual indicator(s) 326 formed on the base 314 can beseen through the covering 316 by a user. Substantially transparentsilicone materials are known and could be used to form the covering 316,as well as other substantially transparent materials. Other than thematerial of the covering 316 being substantially transparent, thecovering 316 is substantially similar to previously described coverings16, 116 and 216.

To form the medical device tray 311, the previously described method offorming medical device trays 11 and 111 can be used with slightmodification. The modification is adding the step of forming a visualindicator 326 on the base 314 adjacent to at least one base through-hole322 and affixing the covering 316 made of a substantially transparentmaterial to the base 314. The visual indicator(s) 326 can be applied by,e.g., printing an ink marking adjacent to the base through-hole 322,forming a notch adjacent to the base through-hole 322, forming anindicating opening adjacent to the base through-hole 322, etc. Printingan ink marking on the base 314 can be accomplished using a variety ofknown substrate printing techniques, such as screen printing, andforming a notch or opening on the base 314 can be accomplished usingetching techniques, such as water jet and laser etching. Applying othertypes of visual indicators 326 to the base 314 can be done in a varietyof known ways, so it should be appreciated that the previously describedmethods are exemplary only and not intended to be limiting.

Forming the visual indicator(s) 326 on the base 314 and then coveringthe base 314 with a substantially transparent covering 316 allows forthe covering 316 to protect the visual indicator(s) 326 from beingremoved. This is especially useful when the visual indicator(s) 326 isan ink marking, as an ink marking on a substrate is usually quite thinand prone to being scratched off or removed by a sterilizing process,such as autoclaving. The covering 316 protecting the visual indicator(s)326 can allow for the visual indicator(s) 326 to survive many uses andcycles of sterilization without being removed, extending the life of thevisual indicator(s) 326 before needing to be re-applied.

While this invention has been described with respect to at least oneembodiment, the present invention can be further modified within thespirit and scope of this disclosure. This application is thereforeintended to cover any variations, uses, or adaptations of the inventionusing its general principles. Further, this application is intended tocover such departures from the present disclosure as come within knownor customary practice in the art to which this invention pertains andwhich fall within the limits of the appended claims.

What is claimed is:
 1. A method of forming a medical device tray forcarrying a plurality of medical devices, said method comprising:providing a base made of a substantially rigid material, said baseforming at least one base through-hole; forming a visual indicator onsaid base adjacent to said at least one base through-hole; and affixinga covering to said base which covers said visual indicator, saidcovering being made of a material which is softer than saidsubstantially rigid material of said base and substantially transparent,said covering forming at least one covering through-hole, said at leastone base through-hole and said at least one covering through-holecooperating to form at least one medical device tray through-hole. 2.The method of claim 1, wherein said substantially rigid material of saidbase is a metal, said material of said covering being biocompatiblesilicone.
 3. The method of claim 2, wherein said affixing comprisesovermolding said covering onto said base.
 4. The method of claim 3,wherein said base includes a plurality of base through-holes.
 5. Themethod of claim 4, further comprising applying a visual indicatoradjacent to each of said plurality of base through-holes.
 6. The methodof claim 5, wherein at least one of said forming and said applyingcomprises screen printing.
 7. The method of claim 4, wherein saidovermolding of said covering fills said plurality of base through-holessuch that said covering includes a plurality of covering through-holescooperating with said plurality of base through-holes to form aplurality of medical device tray through-holes.
 8. The method of claim7, wherein said covering covers an entirety of at least one of a top anda bottom of said base.
 9. The method of claim 2, wherein said metal isstainless steel.
 10. The method of claim 1, wherein said formingcomprises at least one of printing an ink marking adjacent to said atleast one base through-hole, forming a notch adjacent to said at leastone base through-hole and forming an indicating opening adjacent to saidat least one base through-hole.
 11. The method of claim 1, furthercomprising supporting directly a medical device in said at least onemedical device tray through-hole.